Water dispersion of polymerized styrol and product made therefrom



Patented Dec. 15, 1931 1 UNITED STATES PAT T OF I E- T mm A. ernnons, or nomcmun, mew JERSEY, ASSIGNOB mo an inventor onmucsr. comm, or nanearucnconnnc'rrou'r, A oonronarrou or N- N 'ECTICUT warm msrn'nsron or ronmniznn sermon rnonnc'r mum 2|:Hausa'm'iaoni-v 1T0 Drawing.

This invention relates to the production of fibre and meta styrol combinations, more particularly to the provision of such combinations in sheet or slab form. A

5 An object of this invention is to provide a process of producing combinations of fibres and styrol, articularly the polymerized variety where y the styrol is intimately and uniformly associated with the fibres. A

" Ill-further object is to provide a sheet or slab of fibrous material impregnated with polymerized styrol, particularlv the tough variety of meta styrol.

Styrol may be used as such or polymerized to varying degrees of hardness and toughness. The various forms ofstyrol may be used as is found suitable. Where toughness, increased resistance to fracture, increased electrical resistance or increased resistance to water, acids, bases and mineral oils is desirable the normally tough variety termed allpslyia meta styrol as disclosed by Ostromislens s Patent No, 1,683,402 is preferably used. Styrol is a thermo-plastic and this allows molding the sheet or slab into any desired form, for instance such as shoe toe boxes, etc. Accordingly the invention comprises broadly depositing styrol from a solution or disersion thereof upon a paper-making fibre "ea in pulp form, removing excess solvent or dis persing liquid and subsequently forming the mass mto a sheet or slab by drying and calendering or pressing. Theo erations may be carried out with thensua pa er-makin machinery involving the use of a. cater for eatin the ulp,prior to adding the styrol, unti itas nearly reached, the condition'required to form a satisfactory v piper or card makin machinery. 3 The teritself may'be use as an agitator for the fibres and styrol or this may be carrie outinother mixinga thorough mixing of the so at of styrol, the

Where the carrier for the styrol is an organic solvent, thedeposition' is caused; b sheeting the pulp and removing the solvent y the. use} of heat or vacuumor both. Where an aqueous H dispersion ofstyrol is employed,.the styroh sheet on any standardtype of pparatus. After 7 1011 or dispersion styrol is deposited on the fibres. 7

Application filed November e, 19st. Serial no. 493,235.

is deposited in a uniform manner by adding a coagulant for the styrol. Examples of such coagulants are methyl alcohol, barium chloride, alum, ethyl alco ol, acetone. In general it may be said that all coagulating agents for 5 rubber latex serve to coagulate the styrol dispersion.

Styrol in the form of an aqueous dispersion may be prepared as follows: Into an enclosed mixer are introduced 800 grams of dry polymerized styrol (alpha meta styrol).

.To. this are aded 300 grams of xylol and the I of the higher fatty acids may be used such,

as sodium oleate, ammonium'oleate, etc. The fibres are made highly resistant to" water because the alkaliv salt or soaps are largel converted into water insoluble compoun' s1 upon reaction with coagulants such as those containing heavy metals and deposited with the styrol. Where the coagulant afi'ects .principally the styrol and an ammonium salt or soap is used, parts of this's'oap or salt may be caused to remain with. the fibres so that the subsequent drying where heat is employed will remove: the volatile constituent ammonia, leaving aresidue' also contributin to the fibre increased resistance to water e; styrol is preferably softened before dispersion and other means, for instance,

heat may lie-employed instead of softeners a such as 101, toiaccoin li'sh this purposa'j pre erred method of treatin fibres is. indicated as follows'zfcellulosic' bressuoh as-cutcotton rags are. laced in a paperbeater and beaten until t eyr are-sufliciently disintegrateda'nd hydrated; caustic sodais' added, to bring the beater contents; to 9,5100

ins

fairly alkaline condition, so as to guard against any premature coagulation of the styrol. For every 100 parts of fibre there is then mixed therewith from 20 to parts of the polymerized st rol in the form of an aqueous dispersion. fter thoroughly heating the mixture, alum is added until the pH changes to 45.0. The 1p a wet board-makin mac ine and laid down as a fibre mat. This de osit is wet pressed, dried, and d pressed to 've a suitable paper or boar Sizing suc as rosin size, where desired may be incorporated with the mixture, fbr example it may be added to the styrol dispersion before adding the same to the beater, or it ma be added separately. The proportionso st 01 and sizing or filling materials can varied as may be required b the character of the final sheet or'board. he fibre-styrol mixture in the form of sheets from the wet machine when dried at a temperature below the boiling oint of-water andthen each sheet pressed or about 10 minutes at 20# steam ressure with a pressure between platens o apgroximately 1200# per square inch gives a at sheet with fairly smooth surfaces on both sides. It is clear of course that higher steam pressures or subsequent desired hi hei' steam ressures magbe applied to the s eet,

e sheet or board is moldable under heat, or the sheet or board may be first cut and then molded as would be the case in makin articles such as shoe toe boxes, etc. Instea of impregnatin' the aper with a solution or dispersion o styrol; either of these may be mixed with dispers1ons or organic solutions of caoutchouc, reclaimed rubber, asphalt, pitches, balata, natural or ent. Where an aqueous dis ersion is mixed synthetic resins,-etc., or any of thesematerlals may be mcorporated with the fibre separately from the styrol as is found expediwith an or ic solution t e product is a w e in p I pregnate while in sheet, for examp .of' paper which has not -.'been 'su complex co oidal mixture of an aqueous dis rsion and an organosol. 4 gain instead of 1m regnati'n'g the fibres ulp term t e bres ma ime a sheet heavier pressures may be. impregnated with thesolutmn or dispersion of meta styrol.

lhe fibres treated maybe oftvariou's kinds, an mal, vegetable or Jminer'al, {for-example mama, I q H M v It is muchg harder .properties, particularly at ulp is then run to containingla styrol in finel forming t which comprises thorough y mix of cellulosic fibres with an aqueous dispersion outthe mass a meta styrol compound. I I g I 10.- Afibre mass having dispersed cellulosic, asbestos, or': leather.' ij Itlisf t'o' be- .mpderstood that-variouscoinpounding, filling, 'i slzmgecolormgfand anti-ageing'ingredients" 11. Ace ulosic fibre mass having dispersed I employed 1n-..con]unct1on withlthe:

' styrol as is cons1dered-desirable: ;forf the final roduct.- .The producti 'provided herein can so that the product of manufact aper by this invention is stifler, harder, o tter e ectrical resistance and better dielectric high frequencies plaper. Various i styrol may e used in its stead, includi ortho and 333a methyl styrol, symmetri meta-metaethyl styrol, etc., with similar than latex results.

. Having thus described my invention, vwha I claim and desire to protect by Letters Patent is:

1. A process of making fibreproducts which comprises impregnating a mass ,of fibres with a polymerized styrol compound.

2. A process of making fibre products omologues o fibres with a norma ly tough polymerized. I

styrol compound.

4. A process of makin' of cellulosic fibres with an 81311180118 dispersion 'videdform, depositin t e styrol upon e fibres and drymg an forming the mixture into the desired form..

5. A process of makin fibre products I fibre" products which comprises thoroug y mixinga masswhich comprises thorough y amass of cellulosic fibres with an ueous d1 containing a styrol in fine y .divide depositing1 the styrol upon the fibres, e mixture into a sheet or slab.

6. A process 'ofimakin fibre products which comprises thorough y mixing a mass of cellulosic fibres with an aqueous d1 rsion containing a olymerized styrol in'finely divided form fibres and iorming the mixture into a sheet or s a 7. A process of makin fibre products a mass containing a normall tough polymerized styrol in nely divide form, depos ting the styrol upon the fibres, and forming the mixture into a sheet or slab.

tamgbout the mass a normally tough polymermed styrol com and.

throughout the mass anormally tough polymerizedstyrol compound. v ."-;As,:a-new product a fibre sheet intimately associways epositing the styrol upon the a-fibre sheet having rsion form and 14. As anew product a fibre sheet having the fibres uniformly and intimately associated gith a normally tough meta styrol compoun 4 15. As a new product a cellulosic fibre sheet having the fibres uniformly and intimately associated with a st rol compound.

16. As a new pr not a cellulosic fibre sheet having the fibres uniformly and intimately associated with a meta styrol com ound.

17. As a new product a celluloslc fibre sheet having the fibres uniformly and intimately associated with a normally tough meta styrol compound.

18. A fibre-styrol product having the fibres uniformly and intimately associated with a meta styrol compound.

19'. A fibre-styrol product having the fibres uniformly and intimately associated with a normally tough meta styrol compound.

Signed at Passaic, county of Passaic, State of New Jersey, this 24th day of October, 1930.

"r'" II; 1' IS A. GIBBONS. 

